Method and Apparatus to Produce Stretchable Products

ABSTRACT

The invention provides methods and apparatus for producing flexible, stretchable, and/or elastic products comprised principally of material such as natural elastomers and other synthetic polymers. The method and apparatus for producing stretchable products by spraying product material over a workpiece former, and method and apparatus for creating perforated products by spraying product material over a perforated surface or partly breathable surface, The invention also provides methods and apparatus for making double sided fibre coating of the product and, or to at least coating the product surface on the side facing the wall without the need for removing the product from the wall. The method and apparatus also enable easy removal of the product from the former. Workpiece formers are also provided.

CROSS-REFERENCE

This application claims the benefit of U.S. provisional application Ser.No. 60/625,480 filed Nov. 5, 2004, the disclosures of which isincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to methods and apparatus for producingproducts such as two-dimensional and three-dimensional products,composed of flexible, stretchable and/or elastic materials such asnatural elastomers and other synthetic polymers. The invention alsorelates to methods and apparatus for coating the products with fibres,making perforated stretchable and/elastic products, and for removingsuch products from formers.

BACKGROUND OF THE INVENTION

Methods for making products of natural or artificial latex rubbers areknown in the prior art. Such methods include a dipping stage whereby amould is dipped in liquid latex, or a press stage. In order to build upthe latex to a desired thickness and to reduce the product stickiness,several known techniques are used. Examples of such techniques arebased, for instance, on the use of coagulants to control the thickness,diatomite earth products as releasing agent and heating of the mould tobuild up a thicker layer of latex.

However, prior techniques for making products from natural or artificiallatex have a number of disadvantages. For instance, such techniquesresult in products that are often very thin or very thick and areuseless wherein a non-rubber tactile surface feeling is desired,particularly for products that touch skin. In addition, prior techniquesdo not easily allow for releasing and stripping of very thin productsfrom their moulds without damaging the products. Liquid and gas jetshave been used to separate products from their mould, for example,stripping balloons, gloves, and the like. However, the use of liquid andgas jets is inadequate to remove products that are massively perforatedbefore removal from their moulds. Moreover, prior separation techniquesare useless for removing protective garments and bandages which mayinclude absorptive pads as the pad might be damaged.

It is also difficult to control the thickness of latex products usingconventional techniques. For instance, traditional dipping methodsinvolve a mould and a dipping tank wherein the mould is dipped in thedipping tank either in a vertical movement or in a circular movementtowards the liquid latex contained in the tank. A major disadvantage ofthe dipping method is that when a large mould is dipped into the tank,it is almost impossible to keep all parts of the mould dipped for thesame amount of time because the parts dipped first come out last. Thisdisadvantage is not eliminated by the diagonal dipping technique and itis very difficult to achieve a latex layer with even thickness. Inaddition, it is also impossible to selectively control the thickness ofthe layers and to create areas having different thicknesses in the finalproduct. For example, it is difficult or impossible to make productssuch as protective undergarments wherein the thickness of the waist andleg openings are different than that of other parts of the garment.

A further disadvantage of the dipping methods is air bubbles formingalong the surface of the mould and getting trapped underneath the mould.This causes unwanted holes and damage to the surface area of theproduct.

The delicate, and therefore slow, process of dipping as known in theart, makes the methods time consuming, more so when relatively large orcomplex shaped three dimensional moulds are employed.

A further disadvantage of the dipping method is that it forces thedipping of the whole mould, thereby not allowing the cover of specificrequired locations, causing waste in product material.

Furthermore, it is known in the art that latex products may be coatedwith natural or synthetic fibres in order to create a smooth and cosyfeeling for the wearer, particularly where protective garments areinvolved. The fibres are “flocked” over a sticky layer of latex oradhesive on the latex. However, in order to coat a product on bothsides, the steps of stripping the cured latex products from the formerand refitting them on the former for coating the second surface of theproduct are needed and several layers of latex and/or adhesive must beapplied to allow the fibres to adhere. Thus, methods known in the artfor coating latex products with fibres result in increased productthickness and require complex manufacturing processes.

Accordingly, methods are needed to overcome the above-mentioneddisadvantages. In particular, methods are needed to remove products fromtheir moulds without damaging the products; to apply loose fibres easilyto products on one or both sides; to generate perforations in theproduct without the need for stripping the product first or makingadditional steps; and to create products with uniform or varyingthickness in a controlled manner. Thus, the present invention providesmethods that overcome the above-mentioned disadvantages and result inproducts that can be efficiently perforated and efficiently removed fromtheir moulds. In addition, the methods of the invention provides ways toefficiently apply double-sided fibre coatings to products and to createproducts with varying thickness in a controlled manner.

SUMMARY OF THE INVENTION

The present invention is generally related to methods and apparatus forproducing stretchable, elastic or shape-retaining products composedprincipally of materials such as resilient elastomers including but notlimited to natural latex rubber or polyurethane, using controlledspraying of the principal material onto a surface of a wall such as aworkpiece former. The resulting product may have a uniform thickness ordifferent thicknesses at different regions as desired. Differentthicknesses at different regions of a product may be desired toreinforce regions of a product such as leg or waist openings in agarment or reinforced edge of an industrial filter or membrane. Thepresent invention is also directed to methods and apparatus forpreparing products having a single or double-sided surface coating ofloose fibers, a method and apparatus for generating perforations in suchproducts with or without loose fiber coatings, and methods and apparatusfor removing such products off a workpiece former.

In one embodiment of the invention, a method and apparatus for producinga stretchable workpiece is provided. The method comprises: applying afirst layer of loose fibres onto at least a portion of a surface of awall to produce at least a partially fibre-coated product surface, thefirst layer of loose fibres readily removable from the wall surface; andspraying liquid material, e.g. liquid latex, onto the at least partiallyfibre-coated wall surface to form a product material layer on the atleast partially fibre-coated surface and produce the stretchableworkpiece, wherein the product material layer has an inner and outersurface and the fibres are attached to the inner surface of the productmaterial layer. This allows for the formation of products having atleast part of the inner surface—the product surface facing the wallsurface—coated with loose fibres. Walls include two-dimensional workpiece formers such as a flat conveyor belt or a three-dimensionalworkpiece formers having a complex shape to which a workpiecesubstantially conforms. The loose fibres may be made of any suitablematerial including natural or synthetic materials. These materials maybe absorbent. Representative fibres include lightweight cotton fibres orviscose fibres.

In one aspect of this embodiment, the method further comprises the stepof applying a second layer of loose fibres onto the outer surface of theproduct material layer. The loose fibres may be applied directly to theouter surface of the product material layer where the product materiallayer is wet or has not fully dried. Alternatively, the product materiallayer may be dried first and then at least one layer of an adhesive or asecond product material layer is applied to the product material layerto form an adhesion layer. The loose fibers may then be applied to theadhesion layer. This allows for the formation of products having innerand outer surfaces coated with loose fibres.

In another aspect of this embodiment, wherein prior to application ofthe loose fibres, the wall surface is wetted with water or an aqueoussolution so as to allow the loose fibres to temporarily adhere to thesurface before the liquid material spray is applied.

In another aspect of this embodiment, the method further comprises thesteps of: allowing the product material layer to dry; and removing thestretchable workpiece from the surface.

In another aspect of this embodiment, the wall has a perforation or aplurality of perforations. By having a wall with multiple perforations,products may be conveniently formed with holes, to allow for passage ofair or other gases and or liquids. A wall with a single perforation canbe used to generate products with a hole for inserting a connector,tubing, fastener, hooks, and the like. Typically, the liquid materialspraying is carried out such that at least no substantial productmaterial layer forms over the perforations.

In another aspect of this embodiment, the wall comprises breathableconstructed components made of any suitable material such as plastic,composite, or metal. These materials may include pores or openings thatwould make the material permeable to gas or liquid. This would allow airor another gas or liquids to be forced through the wall under suitablepressures either during or immediately after spraying of the liquidmaterial so as to generate holes in the product material layer withoutdamaging the product. Thus, instead of having a wall with built-inperforations to generate holes in the product, gentle gas flow throughthe wall would generate the perforations in the wet product materiallayer.

In another aspect of this embodiment, a vacuum may be applied to theother side of the wall—opposite to the wall sprayed surface—the wallcomprised of breathable constructed material so as to allow loose fibresto temporarily be attached to the surface of the wall prior to liquidmaterial spraying. If desired, the surface of the wall may be wettedwith a wetting agent either prior to or during the application of thevacuum but before the addition of the loose fibres, to furtherfacilitate the temporary adherence of the loose fibres onto the surfaceof the wall.

In another aspect of this embodiment, the workpiece former having ashape to which the workpiece substantially conforms, wherein the wallfurther comprises at least one embedded breathable element to facilitateeasy removal of the product, particularly thin products, withoutdamaging the product. Gas or water, depending on which is moreappropriate, can be forced through the breathable element in order topush or dislodge at least a portion of the workpiece away from thesurface. Preferably, the workpiece has at least one edge, and at leastone breathable element is proximal to the at least one edge so that theedge can be easily lifted from the surface of the wall.

In another embodiment of the invention, a method and apparatus isprovided for producing a stretchable workpiece, the workpiece having atleast one hole or plurality of holes. The comprises: spraying a productmaterial onto at least a portion of a surface of a wall, the wall havinga plurality of perforations, to form a layer of sprayed product materialon the surface and produce the stretchable workpiece having holes,wherein the product material layer has inner and outer surfaces. Thisembodiment may further include a combination of some or all the abovementioned embodiments.

These and other embodiments of the invention will become apparent inlight of the detailed description below.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a representative workpiece mould 100 with a plurality ofbreathing components 105.

FIG. 2 shows a close-up of a representative breathable component 105 inthe form of a hollow tube or finger.

FIG. 3 shows a cross-section of representative mould 100, its internalspace 108, finger 105, air tube 106 and a product 107 attached to theoutwards surface of the mould.

FIG. 4 shows another cross-section of representative mould 100 where air110 is introduced into the mould's internal space through port 106. Theair pushes through the breathing component 105 and pushes at least aportion of the dried product 107 away from the mould.

FIG. 5 is shows a representative apparatus for producing athree-dimensional product comprising a former 100; a positioning device26; a spraying gun 27 for spraying material 29, a movable axis 30, and aproduct 28.

FIG. 6 shows a representative apparatus for producing athree-dimensional product comprising a former 100; a positioning device26; and a controller 31, a spraying gun 27 for spraying material 29, amovable axis 30, a product 28 having holes 32.

FIG. 7 is shows a cross-section of representative former 100 forproducing a three-dimensional product comprising a former wall 35; holesin the wall of the former 33, air tube 107, breathable component orelement 36; product 28, and holes in the product 32.

FIG. 8 is a block diagram on one embodiment of the apparatus.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is generally related to methods for producingstretchable, elastic or shape-retaining products composed of principalmaterials comprising resilient elastomers such as natural latex rubber,polyurethane or other synthetic materials, in a spray able liquid state,using a precise controlled spraying of the liquid material onto asurface of a wall such as a workpiece former. The resulting product mayhave a uniform thickness or different thicknesses at different regionsas desired. Different thickness in different regions of a product may bedesirable in order to reinforce regions of a product such as leg orwaist openings in a garment. The present invention is also directed tomethods and apparatus for preparing products having a flocked single ordouble-sided surface, that is a surface coated with loose fibers, amethod and apparatus for generating perforations in such products, andmethods for removing products off a workpiece former. The presentinvention is also directed to products produced by the inventivemethods, a workpiece former, and apparatus for preparing products basedon product material spraying. The product produced by the invention hasan improved cosy feeling on both sides of the product. A textile-likefeeling and a ‘textile movement noise’ is achieved by using the methodsand former of the invention.

The term “flock” or “flocking” refers to the process of attaching oradhering loose fibres onto a surface.

The terms “former,” “mould,” or “workpiece former” are usedinterchangeably. A former or mould is an object made of any desiredshape or size and serves as shape former for the making of products. Forexample, if a product in the shape of a face mask is desired, then aformer or mould may be constructed that displays the shape and size ofdesired face mask. The former may be flat and two-dimensional such as aflat belt conveyor. Alternatively, the former may be three-dimensionaland have a complex shape to which a workpiece substantially conforms. Inaddition, the former may be made of any suitable material such as metal(e.g., aluminium), porcelain, ceramic, plastics, or composite (e.g.,metal and plastic).

The terms “product” and “workpiece” are used interchangeably and mayalso include any object that can be produced using the methods,apparatus, and formers of the invention. Stretchable, elastic productshave a variety of uses including, without limitation, industrial usesuch as pipes, seals, membranes sheets, filtering membranes; foodindustry such as breathable stretchable wrappers or coverings forobjects including perishables such as food; medical industry for medicalproducts such as dressings and bandages; sanitation, athletic, andpersonal hygiene industries such as garments including protectivegarments and undergarments like brassieres, undershorts, socks, orgloves and any other garment, undergarment or dressing for veterinary oroutdoor use. Other examples of garments are described in U.S. Ser. No.10/723,244, filed Nov. 26, 2003, and in U.S. Ser. No. 09/744,779, filedAug. 5, 1999, both of which are incorporated by reference in theirentirety.

The phrase “loose fibres” refers to any suitable loose flocking fibrematerial including natural or synthetic materials and may behydrophilic, hydrophobic, or a combination of the two. Hydrophilicfibers include wettable fibers, i.e., hydrophobic fibers that have beentreated with a wetting agent to render them hydrophilic, absorbentfibers, and superabsorbent polymer fibers. Examples of wettable fibersinclude bicomponent fibers, polypropylene fibers, and polyester fibersthat have been treated for example with surfactants. Example of wettablefibers are polyester fibers, such as DuPont-Akra Polyester Type 11ABright commercially available from DuPont Company treated with asurfactant such as Tween 20 commercially available from ICI AmericasInc. Absorbent fibers are hydrophilic fibers. Absorbent fibers maycomprise rayon fibers, acrylic fibers, nylon fibers, polyvinyl alcoholfibers, and fibers of natural or regenerated cellulosics. Example ofabsorbent fiber is rayon fibers. Superabsorbent polymer fibers arehydrophilic fibers that are swellable and capable of absorbing greaterthan about 5 grams per gram (of fiber weight) of 1% saline solution.Examples of superabsorbent polymer fibers are polyacrylate fibers,fibers of grafted cellulose, and fibers of maleic acid. Examples ofsuperabsorbent polymer fibers include OASIS Type 101, commerciallyavailable from Technical Absorbents Limited and CAMELOT, commerciallyavailable from Camelot, Alberta, Canada. A preferred fibre for use inthe invention is cotton fibres. Any suitable method for delivering theloose fibres so that they may be applied to the surface can be used. Forinstance, the loose fibres can be sprayed or blown onto the surface ofthe wall as well as electrostatically and or pneumatically flocked.

The phrase “product material” comprises suitable stretchable materialsuch as natural or synthetic polymers. A natural polymer includes,without limitation, latex rubber. A synthetic polymer includes, withoutlimitation, polyurethane. For spraying purposes, emulsions, suspensions,or solutions of the product material, e.g., liquid latex rubber, aregenerally used. After spraying the product material, with or withoutadditional process steps, the product material is preferably allowed todry before it is removed from a surface. The drying process may includecuring or setting processes, depending on the choice of productmaterial. For example, when latex rubber is used as the productmaterial, the latex rubber would cure as it dries. In practicing thisinvention, the preferred product material is natural latex rubber whichforms durable, flexible, stretchable, elastic shape-retaining products.

The term “wall” may refer to a flat or two-dimensional work piece formersuch as a flat conveyor belt or any suitable shaped flat surface towhich a product substantially conforms. Alternatively, the wall may be athree-dimensional workpiece former having a complex shape to which aworkpiece substantially conforms. The wall may be made of any suitablematerials such as plastic, rubber, composite ((e.g. of metal and plasticor ceramic), ceramics, metal such as aluminum or stainless steel.

In one embodiment of the invention, a method for producing a stretchableworkpiece is provided. The method comprises: applying a first layer ofloose fibres onto at least a portion of a surface of a wall to produceat least a partially fibre-coated surface, the first layer of loosefibres readily removable from the wall surface; and spraying liquidproduct material onto the at least partially fibre-coated wall surfaceto form a product material layer on the least partially fibre-coatedsurface and produce the stretchable workpiece, wherein the productmaterial layer has an inner and outer surface and the fibres areattached to the inner surface of the product material layer. This allowsfor the formation of products having at least part of the innersurface—the product surface facing the wall surface—coated with loosefibres, if desired, the method would for further facilitate theproduction of products having inner and outer flocked surfaces asdiscussed below.

Prior to the present invention, the manufacture of products havingdouble flocked surfaces is not easy thing to do. Typically, the outersurface of a product contained on a mould would be initially flocked. Toflock the inner surface of the product, the product is generallystripped off the mould and turned inside out so as to expose theunflocked inner surface. Adhesive material is layered onto the unflockedinner surface, then loose fibres are applied to the adhesive layer.Because of additional mechanical removal and adhesive application steps,the process of producing double sided flocked products can be difficultand expensive, particularly when thin products are involved. The presentinvention provides a surprising and significant improvement of thedouble sided fibre coating procedures by reducing the number of processsteps and entailed costs. Moreover, the present invention provides asurprisingly effective and economical way to produce thin products thatare flocked at their inner and outer surfaces.

Thus, the inner surface flocked product can be used to prepare a doublesided flocked product and in another embodiment of the invention, themethod further comprises the step of applying a second layer of loosefibres onto the outer surface of the product material layer. This allowsfor the formation of products having double-sided flocked (inner andouter) product material surfaces without the need of mechanical removalof the initially flocked product from the former. Preferably the productmaterial layer remains wet or partially wet so that the loose fibres mayadhere to the wet product material surface without the need for anyadded adhesive or extra product material layer. However, if desired, theproduct material layer may be dried and a suitable adhesive or secondproduct material layer may be subsequently applied to the dried productmaterial surface to form an adhesion layer just prior to applying theloose fibres. The dried product material layer may remain or be removedfrom the mould prior to the addition of the adhesion layer.

In another embodiment of the invention, the wall has a perforation or aplurality of perforations. A wall with a single perforation or a fewperforations can be used to generate products with openings forinserting a connector, tubing, fastener, hooks, or other objects. Byhaving a wall with multiple holes or perforations, products may beconveniently formed with breathable perforations, holes, or pores toallow for the escape of perspiration or bodily fluids and enhance thewearer's comfort where the products are used on a body. Theperforations, holes or pores are also useful for flexible, stretchableand/or elastic products that used as filtering membranes to removeparticulates and/or provide gas exchange or as breathable wrappers orcoverings to allow for escape of gases, fumes, or vapours such as watervapour or gas exchange. Typically, product material spraying is carriedout such that at least no substantial product material layer forms overthe perforations. The perforations may be made in the wall of the formeror using breathable components or elements such as disks, rods, hollowtubes or “fingers” or any other shaped component suitable for makingperforations in the product material. These breathable components can bemoulded or embedded into the wall. The generation of perforations orholes in the product may be achieved by careful spraying to preventsubstantial product material layer formation over the perforations or byintroducing a gas such as air, nitrogen, inert gas (e.g., argon), or anyother suitable gas through the holes or through the breathablecomponents when applying or adding the product material to the former,for example, when spraying the product material to the former. The gaspushes through the breathable component and prevents the sprayed productmaterial from forming a layer over the perforation. The perforations maybe circular in shape but may have any desired shape such as stars ortriangles. The perforations may be of any size and can be arranged in arandom fashion or in any suitable pattern or design such as lettering,flowers, or geometric patterns.

In another embodiment of the invention, the wall comprises a breathableconstructed components made of any suitable material such as plastic,composite, or metal such as aluminium or stainless steel. Thesematerials may include pores or openings that would make the materialpermeable to gas or liquid. These breathable materials are commerciallyavailable. For instance, suitable breathable stainless steel materialmay be purchased from Capstan Permaflow (CA, USA); and as Metapor® fromPortec (Switzerland). Walls comprised of breathable material arepermeable and would allow gas to be introduced through the wall duringor immediately after spraying of the liquid product material so as togenerate perforations in the product material layer. Thus, instead ofhaving a wall with built-in perforations to generate holes in theproduct, the flow of gas through the wall of breathable material wouldgenerate the perforations in the wet product material layer. Suitable,but not limiting, examples of gas include air, nitrogen, or an inert gassuch as argon. Suitable, but not limiting, examples of liquids includewater or oil.

As discussed above, the loose fibres may be applied to the surface ofthe wall by any suitable means. These fibres are readily dislodge fromthe wall surface once the layer is removed from the wall surface. Toallow the loose fibres to temporarily adhere to the surface of the wallprior to applying the product material layer, the surface may be wettedwith a suitable wetting agent such as water or any suitable aqueoussolution, e.g., a surfactant solution, prior to the application of theloose fibres. The wetting agent should not interfere with the flockingprocedure or cause any degradation of the product material layer. Uponproduct material spraying, the loose fibres will stick to the productmaterial layer and result in the generation of a inner flocked layer onsprayed product.

The loose fibres may also be temporarily adhered to the surface of thewall using a vacuum. In the situation where the wall is comprised ofbreathable material, a vacuum may be applied to the wall comprised ofbreathable material so as to allow loose fibres to temporarily adhere tothe opposite surface of the wall prior to product material spraying. Thevacuum method for loose fibre adhesion may be used in place of the useof a wetting agent on the surface of the wall or may be used incombination with the wetting agent. For instance, the wetting agent maybe applied to the surface of the wall, the loose fibers are then appliedto the wetted surface, and vacuum is applied to the opposite side ofwall to further secure the attachment of the removable fibers to thesurface. Upon product material spraying, the substantial loose fibresadhering to the surface of the wall will stick to the product materiallayer, resulting in the generation of an inner flocked layer on one sideof the sprayed product material layer.

In another embodiment of the invention, the wall further comprises atleast one breathable element to facilitate easy removal of the product,particularly thin products, without damaging the product. Gas or water,depending on which is more appropriate, can be introduced through thebreathable element in order to push or dislodge the workpiece away fromthe surface of a former (also referred to as a mould). The breathableelement may be located on any suitable region of the wall of a former,usually around the edge of the product. Preferably, the workpiece has atleast one edge and at least one breathable element proximal to the edgeso that at least a portion of the workpiece such as the workpiece edgecan be easily lifted from the surface of the wall to facilitate productremoval from the mould. The breathable element may be embedded into thewall or is part of the integral wall structure and provides a discreteopening or porous region or zone in the wall to allow gas or water (orother suitable liquid) to pass. Examples of breathable elements mayinclude any suitable shape including hollow tubes or “fingers”, disks,rods. These breathable elements may be created has part of a former orembedded into the former. These elements may be made of the samematerial as the former or any other suitable material such as aluminium,composites (e.g., metal and plastic), plastics. These special breathablecomponents may be connected, through air tubes, to an air compressor orother gas source. When removing or stripping the product from the formeris desired, the compressor is used to push air through the breathablecomponents, which result in the product being pushed away off the formeror mould. At this stage it is also possible to catch the product's edgesand strip it off the mould, either by manual or mechanical means.

In all of the embodiments described herein, once the workpiece iscompleted, including any additional flocking steps, it is desirable toallow the product material layer to dry prior to removal of theworkpiece from the surface of the wall so that to prevent damage to theworkpiece.

In some instances, the direct spraying of liquid product material onto asurface of a wall having no adherent loose fibres may be desired. Thus,in another embodiment of the invention, a method is provided forproducing a stretchable workpiece, the workpiece having a plurality ofperforations. The method comprises: spraying a liquid product materialonto at least a portion of a surface of a wall, the wall having oneperforation or a plurality of perforations, to form a product materiallayer on the surface and produce the stretchable workpiece having one ormore perforations. If desired, the product material layer can be driedand the resulting workpiece may be removed from the surface, or the wetor partially wet product material layer can be flocked.

As discussed above in other embodiments of the invention, the wall mayfurther comprise at least one embedded breathable element to facilitateeasy removal of the product, particularly thin products, withoutdamaging the product.

The direct spraying of liquid product material onto a surface of a wallcomprised of breathable material as described above and further havingno adherent loose fibres may also be desired. Thus, in anotherembodiment of the invention, a method is provided for producing astretchable workpiece, the workpiece having a plurality of perforations.The method comprises: spraying a liquid product material onto at least aportion of an outer surface of a wall to form a product material layer,the wall comprised of breathable material; and applying gas undersuitable pressure to an inside surface of the wall and opposite theproduct material layer to generate a plurality of perforations in theproduct material layer and produce the stretchable workpiece. Thebreathable material may include pores or openings that would make thematerial permeable to gas. This would allow gas to pass through the wallunder suitable pressures and into the wet product material layer so asto generate perforations in the product material layer without damagingthe product. Thus, instead of having a wall with built-in perforationsto generate holes in the product, gentle gas flow through the wall wouldgenerate the perforations in the wet product material layer. If desired,the product material layer may be flocked on one or both sides asdiscussed above.

In another embodiment of the invention, a workpiece former is provided.The workpiece former comprises: a wall enclosing an internal space, thewall having at least two portions, a first portion of the wall having ashape to which a workpiece would substantially conform; a plurality ofbreathable elements associated with the first portion of the wall; andat least one port for introducing vacuum, gas or liquid into theinternal space, the port associated a second portion of the wall. Gas orliquid introduced into the internal space via the port would passthrough a plurality of breathable elements under sufficient pressure soas to push the workpiece away from the first portion of the wall, thusallowing for easy removal of the product from the former. In thesituation where a workpiece has at least one edge, it is preferred thatat least one breathable element associated with the first portion of thewall is proximal to at least one edge of the workpiece. This would allowa portion of the product to lift off the former and allow for easyremoval of the product from the former. As discussed above, the wall maybe comprised of any suitable porous or breathable material. A workpieceformer having a wall of breathable material is desirable as theapplication of vacuum via the port would allows for the attachment ofloose fibres onto the surface of the wall prior to product materialspraying as described above. The porous wall would also allow for thepassage of gas during or after product material spraying to allow forthe generation of perforations or holes in the product material productas discussed above. The workpiece former may include a movable axis forrotating and/or moving the former to any suitable operating position.The workpiece may further include a plurality of perforations or holesin any shape or size to create a desired perforation pattern in theworkpiece. In addition, some or all of the breathing elements mayfurther comprise tubes for the delivery of gas or liquid under suitablepressure to dislodge at least a portion of the workpiece off the mould.

In another embodiment of the invention, a workpiece former is provided.The former comprises: a wall enclosing an internal space, the wallhaving at least two portions, a first portion of the wall having a shapeto which a workpiece would substantially conform; at least onebreathable component associated with the first portion of the wall; andat least one port for introducing gas or liquid through the breathablecomponent, the port associated with a second portion of the wall and influid connection with the breathable component. When gas or liquidthrough the breathable component under suitable pressure, the gas orliquid would push at least a portion of the dried workpiece away fromthe first portion of the wall, facilitating the removal of the workpiecefrom the former. In the situation where the workpiece has at least oneedge, it is preferred that at least one breathable element is proximalto at least one edge of the workpiece. In one aspect of this embodiment,the first portion of the wall may further include a plurality ofperforations and the former further comprises a second port for theintroduction of gas into the interior space. This would allow for theoption of introducing gas to prevent or to blow out any product materialfilms that inadvertently form over and block the perforations. Inanother aspect of this embodiment, at least the first portion of thewall further comprises breathable material and the former furthercomprises a second port for the introduction of vacuum or gas into theinterior space. This would allow for the introduction of vacuum which inturn allows for the attachment of loose fibres onto the surface of thewall prior to product material spraying. As before, the former mayfurther comprise means for moving and/or rotating the former to aplurality of operating positions. FIG. 7 provides a representativeexample of this workpiece former. The former includes wall 35 which mayinclude a plurality of optional perforations or holes 33 and abreathable component 36 which is connected to an air tube 107. A driedproduct 28 including a hole or perforation 33 is attached to the wall35. When air is introduced into air tube 107 under suitable pressure, itflows through breathable component 36 and the pressure of the introducedair causes at least a portion of product 28 to be pushed off the wall.

In another embodiment of the invention, a workpiece former is provided.The workpiece former comprises: a wall enclosing an internal space, thewall having at least two portions, a first portion of the wall having ashape to which a workpiece would substantially conform; a plurality ofperforations associated with the first portion of the wall; and at leastone port for introducing vacuum, gas or liquid into the internal space,the port associated a second portion of the wall. If the perforationscompletely traverse the wall of the former, gas introduced into theinternal space via the port would pass through a plurality ofperforations and push away or eject any product material film blockingthe perforation on the former to ensure the creation of a plurality ofperforations in the workpiece. A plurality of optional breathableelements may be included in the first portion, preferably near an edgeof the work product. These breathable elements further comprise tubes soas to allow the introduction of gas or liquid under sufficient pressureso as to push the dried workpiece away from the first portion of thewall, thus allowing for easy removal of the product from the former. Theworkpiece former may include a movable axis for rotating and/or movingthe former to any suitable operating position.

FIG. 1 illustrates a representative workpiece former in the shape ofunderpants. The former has a plurality of embedded breathing components105 positioned such that they are proximal to the edges of the leg andwaist openings. The workpiece former includes a port 106. FIG. 2 is aclose-up view of an isolated breathing component in the shape of ahollow tube or finger.

In another embodiment of the invention, a method is provided fordislodging a workpiece from a surface of a workpiece former, theworkpiece former having a shape to which the workpiece substantiallyconforms and comprising at least one embedded breathable element, saidmethod comprising introducing gas or liquid through the breathableelement embedded in the workpiece former under sufficient pressure so asto push the workpiece away from the workpiece former. This method may beperformed, for instance, as shown in FIGS. 3 and 4. As shown in FIG. 3,the workpiece former comprises a wall 100 surrounding or enclosing aninterior space 108. In FIG. 4, a gas 100, e.g., air, may be introducedinto the interior space through port 106. The gas passes throughbreathing component 105, pushing at least a portion of product 107 awayfrom the mould so that an operator can readily grip and lift the productoff the mould.

In another embodiment of the invention, an apparatus for producing astretchable workpiece is provided. The apparatus comprises a wall, thewall may have single hole or a plurality of perforations to generateperforations in the workpiece; and a sprayer to generate a liquidproduct material spray onto the wall surface.

In one aspect of this embodiment the wall surface is a workpiece formerhaving a shaped portion to which a work piece substantially conforms

In another aspect of this embodiment the wall surface is a complex shape3D workpiece former.

In further another aspect of this embodiment the wall surface is a flatsurface.

In further another aspect of this embodiment the wall surface is aconveyer belt.

In one embodiment of the invention, the apparatus further comprises apositioning device associated with the sprayer or with the wall.

In another embodiment of the invention, the wall further comprises oneor more breathable elements embedded in the wall, and a source of a gasor liquid for pushing the workpiece away from the wall.

In another embodiment of the invention, an apparatus for producing astretchable workpiece is provided. The apparatus comprises a workpieceformer and one or more sprayers, at least one sprayer directed tospraying liquid product material. An optional positioner for the sprayermay be further included in the apparatus. An optional controller maybeused as part of a positioner system. Representative apparati forpreparing stretchable workpieces are shown in FIGS. 5 and 6. Anysuitable workpiece former may be used as part of the apparatus,including flat, two-dimensional or three-dimension workpieces having acomplex shape to which the workpiece substantially conforms. Inpracticing this invention, the workpiece formers of the invention arepreferred.

Any suitable sprayer or spraying system may be employed in practicingthis invention. For spraying liquid product material, wetting agent, orloose fibers to the former, suitable sprayer or sprayer system mayinclude, without limitation, air assisted based, airless based,electrostatic-based sprayers. In addition to the spray gun, thesesprayers or sprayer systems may further include compressors, pressuretanks, pressure regulators, feeding pipes and other components known inthe art for straying liquid polymers, elastomers such as latex, andother like materials. Representative dedicated airless guns for sprayingliquid latex are commercially available for Graco N.V. of Belgium and bySpraying Systems Co. of IL, USA. The sprayer or sprayer system mayconsist of a single product material spray gun or may include additionalspray guns for a variety of purposes such as creating different widthsof spray bands, for spraying different compositions such as wettingagents or adhesives or for delivering different materials such ascoloured materials or agents or loose fibers. The spray guns preferablyhave a variable fan facility to enable the creation of thicker bands orlayers of product material at desired areas.

For flocking loose fibers onto wet product material or adhesive layer oron a wetted surface, a separate flocking machine may be usedindependently of the sprayer system used for spraying materials. Theflocking machine may be a pneumatic, electrostatic or combined flockingmachine suitable for flocking natural or synthetic loose fibres over wetsurfaces.

In another embodiment of the invention, the apparatus may furthercomprise a positioning device for precise controlled of the spray gunmovements. In one embodiment, the positioning device may be a roboticarm dedicated for spraying such as the robotic arm manufactured by FanucRobotics, ABB, Staubli for spraying paint or any other suitablemechanical device as known in the art, capable of moving the spray gunor the former or both in a precise controlled manner. RepresentativeFIG. 5 illustrates the preparation of a workpiece using a workpieceformer 100, a sprayer for spraying product material 27 and a positioningdevice 26 for positioning the sprayer as shown in FIG. 5. As shown inFIG. 5, liquid product material 29 is sprayed onto a former 100 as theformer is being rotated along its movable axis 30. The movable axis 30also allows for the adjustment of the former along any angle for providefor different operational positions. As product 28 is being formed, theposition of either the former, the positioner or both are adjusted.

In yet embodiment of the invention, the positioning device 26 isassociated with a controller that adjusts the positional relationshipbetween the spray gun 27 and the mould 100, adjust the fan pattern andcontrol material atomisation and amount of liquid material per givenunit of time. This will, in turn, allow for the precise control of thethickness of the sprayed layer. An increase in thickness will then bepossible through repeat spraying of specific areas, slower movment overspecific areas or heavier flow of the sprayed product material overspecific areas. For example, to increase the thickness of the edge of amembrane for the purpose of reinforcing and strengthening the product.The positioning device may independently (or through the controller)control the timing and duration of spraying and will, in another aspectof this embodiment, enable the production of a multicoloured product andvarious thicknesses within it. Representative FIG. 6 is identical toFIG. 5 except that a separate controller is added to automaticallyadjust the position of either the former, the positioner, or both, basedon data and instructions inputted into the controller. The controllermay also adjust the rate of delivery of sprayed product and spray fanangle. If the sprayer is a system that includes a plurality of sprayguns for spraying product material, wetting agent, loose fibres, orother materials, the controller may activate and control each individualspray gun and in a particular sequence. Alternatively, a plurality ofdedicated positioners may be used, each positioner associated with asprayer and all under the control of a single controller. Although notshown, a positioning sensor may be placed on the positioner, on thesprayer, or former so that distance and/or angle data between thesprayer and the former can be collected and processed by the controller.

In another aspect of this embodiment, the apparatus may further comprisea vacuum system and a system for delivering loose fibres to theworkpiece former. The vacuum allows the fibres to adhere to the former,with or without the use of a wetting agent as described above.

In another aspect of this embodiment, the workpiece former may beperforated to allow for the production of products having perforationsor holes as described above. In addition, the workpiece former mayinclude one or more breathable elements embedded in the former. Thus,the apparatus may further include a source of a gas or liquid forpushing the workpiece away from the former. The source of the gas may bean air compressor. The source of the liquid may be a water reservoirattached to a pump.

In another embodiment of the invention, an apparatus and system isprovided for preparing a stretchable workpiece which employs a workpieceformer, a sprayer, a positioner for the sprayer or former, and acontroller whereby the controller adjusts the positional relationshipbetween the former and the sprayer by moving the former, the sprayer, orboth simultaneously. By proper positioning of the former and sprayerrelative to each other, the sprayer may then properly spray the desiredregions of the former. The system provides a fast and accurate way forspraying three-dimensional complex shaped formers to providethree-dimensional stretchable workpieces.

Referring to FIG. 8, a representative block diagram of the system isshown. A controller 31 controls the operation of the system. Examples ofa controller include, but are not limited to, a computer, a terminal, aworkstation, or some other electronic device capable of controlling theoperation of the positioning device 26 and the former 100. Thecontroller 31 includes a processor 12 and a memory 14. The processor 12may comprise a microprocessor, a microcontroller, or any device whichperforms arithmetic, logic or control operations. The memory 14 mayinclude any suitable memory device such as non-volatile memory devicessuch as a ROM, or magnetic or optical memory. The memory 14 may alsoinclude volatile memory devices such as a RAM device. Software may beincluded for the controller to control components within the system,such as the positioning device 26 and former 100.

The controller 31 communicates with the positioning device 26, asdescribed in more detail below. The positioning device 26 includes atleast one motor 18 for moving a sprayer 27 (or alternatively moving theformer 100). The positioning device 26 may further include at least onesensor 20 for sensing the position of the sprayer 27 (or alternativelysensing the position of the former 100). In an alternate embodiment, thesensors may be located within the controller 31. In one embodiment, thepositioning device 26 may be a robotic device as discussed above.

In all the above mentioned embodiments sensing the relative positionbetween the workpiece former and the spraying system may be provided byany other means, including, but not limited to, software, memory,mechanical routines.

A method for preparing a workpiece may be performed as follows. Theformer 100 and sprayer 27 may be positioned relative to the former 100.In one embodiment, the former 100 is positioned, by a positioning device26 using motors 18, to a process starting point where the spray systemand the workpiece former are in proper working position. In an alternateembodiment, the sprayer 27 is positioned by the positioning device 26 toa process starting point. In still an alternate embodiment, both theformer 100 and the sprayer 27 may be positioned by the positioningdevice 26.

The sprayer 27 may include a variety of controllable parameters.Examples of the parameters include, but are not limited to, amount ofliquid material delivered as a function of time, fan pattern, direction,controlled material atomization, and spray gun activation. Theparameters for spray operation may be set automatically or manually. Ifset automatically, the parameters may be determined by accessing thememory 14 which stores the parameters for operation of the sprayer.Alternatively, the sprayer may scan the product using a sensor orsensors (such as a sensor or sensors included with the positioningdevice 16) on the former to determine aspects of the initial productsuch as material, thickness, color, etc. of the product. Based on thisdetermination, the memory 14 may be accessed to set the parameters forthe sprayer based on the aspects of the product so that furtheroperation steps such as additional spraying of product material bands orlayers at specific regions of the initial product for reinforcement maybe performed.

After the first step of spraying, the positioning device 26 preferablyrepositions the former 100 or the sprayer 27, so that the new positionon the former 100 is at the effective distance and angle of spray 29. Inone embodiment, the positioning device 26 moves or rotates the former100 in front of the sprayer 27 according to data received from thedistance determiner (not shown) and the sensing system 20.Alternatively, the positioning device 26 moves the sprayer 27. Inanother alternative embodiment, the positioning device 26 moves both theformer 100 and the sprayer 27.

The distance between the former 100 and the sprayer along the processcan be pre-set for all the steps of the spraying process, for instanceby mechanical routine, by software, or by any other suitable methodknown in the art so the positioning device 26 will correct the relativeposition between the workpiece former and the spraying system, duringthe movements along the production process.

Alternatively, the determination and adjustment of relative position canbe done in real-time by a measurement or sensing device, such as anoptical device, ultrasonic device (for example, the one or more sensors20 on the positioning device 26), any other proximity sensing device orother devices known in the art, and the data can be transferred to thecontroller 31 and to the positioning device 26 for appropriateadjustment of the location of the former 100.

Referring to FIG. 5, there is shown a perspective view of a workpiecebeing made on the former 100 with sprayer 27. The former 100 may beconnected to a robotic device (which functions as the positioning device26). The connection may be made by attaching pole 44 on the former 100to the robotic device. The former 100 may then be moved. The roboticdevice may move the former 100 in any direction and to any position sothat the spray 29 may contact any portion on the former 100. Forexample, the sprayer 27 may remain stationary, focusing the spray 29 ona middle portion of the former 100 and the robot may move the former 100in a circular direction so that the spraying occurs along thecircumference of former 100.

One example of the operation of the system is as follows. An industrialrobot positions the former 100 using motors 18 of the positioning device16 in front of sprayer 27 at such a distance that spray will contact atleast a portion of the former 100. The parameters of spray 29 may alsobe adjusted to give optimal performance instead of, or in addition tochanging the relative position between sprayer 27 and the former 100.

The former 100 may then be rotated and repositioned by the robot, sothat the next area to be sprayed is facing the sprayer 27, atsubstantially the same distance and substantially at the same angle tothe spray 29.

If the former 100 shape is complicated, the robot may be required tomake horizontal, vertical, and rotation movements, in order to bring theformer 100 to the correct position in three-dimensional space relativeto the sprayer. Accordingly, the robot may be required to work in anynumber of axes.

The movement of the former 100 in front of the sprayer 27 can be done ina continuous and smooth manner, with all movements in all axes beingdone simultaneously so that with continuous spraying by sprayer 27,formation of the work piece can be achieved quickly. Alternatively,movement of the former 100 in front of sprayer 27 be performedstep-by-step, in the case of where additional layers or bands of liquidproduct material or other materials may be sprayed on an existingproduct material layer to thicken and reinforce different areas of theproduct or to add other materials such as loose fibres. In this manner,there is no need to remove the product (such as a garment) from theformer 100 in order to produce double-sided flocked garments or otherproducts.

Thus, in one aspect of the invention, an apparatus is provided forpreparing a workpiece that conforms to a former. The apparatuscomprises: (a) a workpiece former having a shape to which the workpiecesubstantially conforms; (b) a sprayer to generate a liquid productmaterial spray; and (c) a positioner that makes an adjustment to keepthe spray substantially focused on the workpiece during the sprayingprocess. If desired, the workpiece former may further comprise a movableaxis to enable rotation and movement to a plurality of operatingpositions. Adjustments may be made by moving the workpiece former in adirection that changes the distance and angle between the former and theliquid product material sprayer. Alternatively, the adjustment may bemade by moving the liquid product material sprayer in a direction thatchanges the distance between the former and the liquid product materialsprayer. The adjust may be made by moving the sprayer or moving theformer or both. The workpiece may be flat or two-dimensional.Alternatively, the workpiece may be three-dimensional and the workpieceformer has a complex shape to which the workpiece substantiallyconforms.

In another aspect of this embodiment, the apparatus further comprises: aprocessor; a memory; and a set of instructions stored in the memory andexecutable by the processor to move the sprayer and to cause thepositioner to make the adjustment based on data stored in the memorythat correlates the change in effective position to the sprayer to theworkpiece, to adjust spray fan pattern, and to adjust amounts of liquidproduct material delivered per unit of time. The positioner maycomprises a position sensing device (such as an optical sensor orultrasonic sensor) and a motor. If desired, the positioner may operatein real-time to make the adjustment using input from the positionsensing device. If desired, the sprayer comprises a plurality ofdifferent spray guns, at least one spray gun generates the liquidproduct material spray. Alternatively, the sprayer comprises a pluralityof different spray guns, at least one spray gun generates the liquidproduct material spray, and another spray gun generates a loose fibrespray. Alternatively, the sprayer comprises a plurality of differentspray guns, at least one spray gun generates the liquid product materialspray, a second spray gun generates a loose fibre spray and a thirdspray gun generates a water spray.

In another aspect of this embodiment, the adjustment further comprisesactivating a spray gun.

In another aspect of this embodiment, the workpiece former includesperforations, breathable elements embedded in the former, or both. Theworkpiece former may be any suitable former, preferably the formers ofthe present invention.

In another embodiment of the invention, an apparatus for preparing aworkpiece using a liquid product material spray produced by a sprayer isprovided. The apparatus comprises: a workpiece former, the workpieceformer being movable to a plurality of operating positions and having ashape to which the workpiece substantially conforms; a positionercomprising a position sensing device; a processor; a memory; and a setof instructions stored in the memory and executable by the processor tomove the sprayer to an operating position and to cause the positioner tomake the adjustment to the sprayer to keep the liquid product materialspray substantially focused on the workpiece during the sprayingprocess. The adjustment being made using input from the position sensingdevice. The workpiece former may be flat or two-dimensional.Alternatively, the workpiece former may be three-dimensional and have acomplex shape to which the workpiece substantially conforms.

In another embodiment of the invention, an apparatus is provided forpreparing a workpiece using a sprayer comprising a spray gun forgenerating a liquid product material spray, a spray gun for generating awetting agent spray, and a spray gun for generating a loose fibre spray.The apparatus comprises: a workpiece former, the workpiece former beingmovable to a plurality of operating positions and having a shape towhich the workpiece substantially conforms; a positioner comprising aposition sensing device; a processor; a memory; and a set ofinstructions stored in the memory and executable by the processor tomove the sprayer to an operating position, to activate a spray gun, andto cause the positioner to make the adjustment to the sprayer to keepthe spray substantially focused on the workpiece as the positioner movesthe sprayer to an operating position that changes the distance andrelative angle between the workpiece and the spray due to the complexshape of the workpiece former, the adjustment being made using inputfrom the position sensing device. The workpiece former may be flat ortwo-dimensional. Alternatively, the workpiece former may bethree-dimensional and have a complex shape to which the workpiecesubstantially conforms.

In another embodiment of the invention, a method is provided forpreparing a three-dimensional workpiece that conforms to a workpieceformer having a complex shape, the method using a liquid productmaterial spray, a loose fibre spray, and an optional wetting agentspray, each spray produced by individual spray guns of a sprayer. Themethod comprises: changing the positional relationship between thesprayer and the workpiece former to establish a first operating positionwhere the surface of the workpiece is substantially at the effectivedistance where the spray meets the workpiece; changing the positionalrelationship between the sprayer and the workpiece former to establish asecond operating position that changes the distance between theworkpiece and the sprayer due to the complex shape of the workpieceformer; and making an adjustment to keep the spray substantially focusedon the workpiece at the second operating position.

In one aspect of this embodiment, the adjustment comprises moving theworkpiece former in a direction substantially parallel to an axis aboutwhich the spray is symmetric.

In another aspect of this embodiment, the adjustment comprises movingthe sprayer in a direction substantially parallel to an axis about whichthe spray is symmetric.

In another aspect of this embodiment, the method further comprises:sensing the change in distance and/or the angle between the workpieceand the sprayer caused by changing the positional relationship betweenthe sprayer and the workpiece former from the first operating positionto the second operating position, wherein the adjustment is made inresponse to the sensed change.

In another aspect of this embodiment, the method further comprising:referring to data stored in a memory that correlates the change indistance and/or angle between the workpiece and the sprayer to motionfrom the first operating position to the second operating position,wherein the adjustment is made in response to the data stored in thememory.

In another embodiment of the invention, a method is provided forproducing a three-dimensional workpiece that conforms to a workpieceformer having a complex shape, the method using a liquid productmaterial spray produced by a sprayer. The method comprises: establishinga first operating position where the surface of the workpiece former isat an effective distance where the liquid product material spray meetsthe workpiece former; activating the sprayer to generate a liquidproduct material spray onto the workpiece former; changing thepositional relationship between the sprayer and the workpiece former toestablish a second operating position where the surface of the workpieceis at an effective distance where the liquid product material spraymeets the workpiece former; activating the sprayer; changing thepositional relationship between the sprayer and the workpiece former toestablish a second operating position that changes the distance and/orangle between the workpiece and the sprayer due to the complex shape ofthe workpiece former; and making an adjustment to keep the liquidproduct material spray substantially focused on the workpiece at thesecond operating position.

In one aspect of this embodiment, the method further comprises:deactivating the sprayer before establishing the second operatingposition; and activating the sprayer after the second operating positionis established.

In another aspect of this embodiment, the sprayer remains activated asthe positional relationship between the sprayer and the workpiece formeris changed.

In another embodiment of the invention, a method is provided forpreparing a workpiece that conforms to a shape of a workpiece former,the method using a liquid product material spray produced by a sprayer.The method comprises: changing the positional relationship between thesprayer and the workpiece former to establish a first operating positionwhere the surface of the workpiece is substantially at the effectiveposition where the spray meets the workpiece; changing the positionalrelationship between the sprayer and the workpiece former to establish asecond operating position that changes the relative position between theworkpiece and the sprayer due to the shape of the workpiece former; andmaking an adjustment to keep the liquid product material spraysubstantially focused on the workpiece at the second operating position.The former may be flat or two-dimensional. Alternatively, the former maybe three-dimensional and the workpiece substantially conforms to thecomplex shape of a workpiece former.

In one aspect of this embodiment, the adjustment comprises moving theworkpiece former in a direction substantially parallel to an axis aboutwhich the liquid product material spray is symmetric.

In another aspect of this embodiment, the adjustment comprises movingthe sprayer in a direction substantially parallel to an axis about whichthe liquid product material spray is symmetric.

In another aspect of this embodiment, the method further comprises:sensing the change in distance and/or angle between the workpiece andthe sprayer caused by changing the positional relationship between thesprayer and the workpiece former from the first operating position tothe second operating position, wherein the adjustment is made inresponse to the sensed change.

In yet another aspect of this embodiment, the method further comprises:referring to data stored in a memory that correlates the change inrelative position between the workpiece and the sprayer to motion fromthe first operating position to the second operating position, whereinthe adjustment is made in response to the data stored in the memory.

In another embodiment of the invention, a method is provided forproducing a workpiece that conforms to a shape of a workpiece former.The method using an liquid product material spray, a loose fibre spray,and an optional wetting agent spray produced individual guns of asprayer, the method comprising the following steps in order:establishing a first operating position where the surface of theworkpiece former is at an effective position where the liquid productmaterial spray meets the workpiece former; activating a spray gun of asprayer to generate a spray onto the workpiece former; changing thepositional relationship between the sprayer and the workpiece former toestablish a second operating position where the surface of the workpieceis at an effective position where the liquid product material spraymeets the workpiece former; activating a spray gun of a sprayer togenerate a spray; changing the positional relationship between thesprayer and the workpiece former to establish a second operatingposition that changes the distance and/or angle between the workpieceand the sprayer due to the complex shape of the workpiece former; andmaking an adjustment to keep the spray substantially focused on theworkpiece at the second operating position. The former may be flat ortwo-dimensional. Alternatively, the former may be three-dimensional andthe workpiece substantially conforms to the complex shape of a workpieceformer. In one aspect of this invention, the method further comprises:deactivating the sprayer before establishing the second operatingposition; and activating the sprayer after the second operating positionis established. In another aspect of this invention, sprayer remainsactivated as the positional relationship between the sprayer and theworkpiece former is changed.

It will be appreciated by persons skilled in the art of that the presentinvention is not limited by what has been particularly shown anddescribed hereinabove. Rather the scope of the present inventionincludes variations and modification of the various features describedin the specification and shown in the drawings which may occur to aperson of ordinary skill in the art upon reading the foregoingdescription and which are not in the prior art.

1-100. (canceled)
 101. An apparatus for producing a stretchableremovable workpiece, the apparatus comprising: (a) A workpiece former;(b) a controllable spraying system for spraying wetting agent or productmaterial onto the former, the spraying system comprising a plurality ofspraying guns for spraying the same or different materials; (c) apositioning device associated with the spraying system, or with theworkpiece former or with both, wherein the positioning device adjuststhe relative position between the workpiece former and the sprayingsystem; and (d) a flocking sprayer or flocking machine
 102. Theapparatus according to claim 101, wherein the positioning device is arobot.
 103. The apparatus according to claim 101, wherein the sprayingsystem comprises at least one electrostatic-based sprayer.
 104. Theapparatus according to claim 101 or 103 wherein at least one sprayinggun is used to spray the wetting agent, and at least one sprayer is usedto spray the product material.
 105. The apparatus according to claim101, wherein the workpiece former is a two-dimensional former or athree-dimensional former.
 106. The apparatus according to claims 101 and105, wherein the workpiece former further comprises a porous or abreathable material or at least one breathable component.
 107. Theapparatus according to anyone of claims 101, 105 and 106 wherein theworkpiece former further comprises a single perforation or a pluralityof perforations.
 108. The Apparatus according to anyone of claim 101,105, 106, or 107, wherein the former is a conveyer belt.
 109. Theapparatus according to claim 101, further comprising: (i) a processor;(ii) A memory; and (iii) A set of instructions executable by theprocessor, during the spraying process, to adjust at least one of: a)the relative position of the sprayer to the workpiece former; b) theeffective distance from at least one sprayer to the workpiece former; c)the relative angle between at least one sprayer to the workpiece former;d) the fan pattern; e) the amounts of sprayed material delivered perunit of time; or f) material atomization.